Safevent Systems, Woolston - SME (Manufacturing)

A free resource efficiency review by a local ENWORKS adviser has uncovered potential savings of over £65,000 a year at the Safevent windows and glazing factory in Woolston, Warrington.

Safevent Systems Ltd is the manufacturing arm of the Warrington-based Britplas Group, which specialises in the manufacture and installation of all types of commercial glazing.

As an SME with high energy and fuel costs, Britplas was keen to keep its costs down and reduce its environmental impact, to help retain a competitive edge.
 
Free support
 
The business is receiving ongoing support from a specialist adviser atGroundwork Cheshire, with funding from the North West’s ENWORKS programme.
 
It has already implemented a number of actions from its initial site review, which have together generated annually recurring savings of £23,400 and 74 tonnes of carbon dioxide equivalent (CO2e).
 
Work is now underway to tackle the rest of the identified improvements, which could save a further £42,100 and 162 tonnes of CO2e a year.
 
Completed projects
 
Britplas runs a fleet of 20 vans that each covers about 30,000 miles a year on average. Their high fuel costs have been addressed by organising fuel efficient driving training for all drivers, improving vehicle maintenance practices and monitoring diesel consumption through dashboard sat-navs.
 
As a result, the company has made annually recurring savings of £15,000 and 28 tonnes of CO2e, from an outlay of just £500.
 
A further £2,900 and 14 tonnes of CO2e per year have been saved by implementing routine monitoring procedures for utilities on site and identifying key areas where consumption can be reduced.
 
Plastic curtains and partitions have also been fitted over four large, roller shutter doors, to prevent heat loss from the factory floor. These have generated annual savings of £2,300 on heating bills, with a payback period of just two years, and saved 13 tonnes of CO2e per year.
 
Meanwhile, a 24-hour timer on the office boiler has been replaced with a more flexible, seven-day timer that allows the heating to be turned off at weekends and overnight. For just £250 this has saved over £2,000 on annual gas bills.
 
New projects
 
The next phase of the efficiency drive is to look at installing motion and light level sensors, to make sure that artificial lighting is only used when necessary. This could save £3,800 and over 19 tonnes of CO2e a year, at minimal cost.
 
A new radiant heating system in the warehouse could also save £8,700 and 50 tonnes of CO2e annually, and replacing a 15-year-old boiler with a more energy-efficient model would save £1,500 and eight tonnes of CO2e per year, after an initial five-year payback.
 

Case study published on 12 July 2012